Molded Railroad Composite Cross Tie Unit

ABSTRACT

A molded composite cross tie and two molded, non-metallic composite tie plates are molded into a single molded railroad composite cross tie unit. The molded railroad composite cross tie unit is fully assembled and ready for laying a ballast and accepting railroad track. The molded, non-metallic composite tie plates are molded with a cant onto which railroad track may be laid. The railroad track is secured by either traditional spikes or screws. When secured by screws, holes are molded with thread that is compatible with the screws used to hold the railroad track in place. One molded, non-metallic composite tie plate is molded into each end of the molded composite cross tie. The separation between the two molded, non-metallic composite tie plates is determined by the gauge of the railroad track.

CROSS REFERENCE

The present application claims benefit of U.S. Provisional PatentApplication, No. 62/889,805, filed Aug. 21, 2019, which is herebyincorporated by reference herein in its entirety, including but notlimited to those portions that specifically appear herein.

FIELD OF THE INVENTION

Improved construction of railroads may be accomplished by replacingseparate components used for railroad track installation with a singlemolded unit.

Typically railroad track is laid on steel tie plates attached to woodencross ties. The tie plates are designed with a pre-determined cant andshoulders to help keep the track in place, and the track and the tieplates are then attached to railroad ties using metal spikes. The railis laid into the steel tie plates and secured with spikes or screws.

The invention disclosed herein describes a novel molded integrated unitcomprising railroad cross ties and tie plates designed to be placed on arailroad bed configured to receive the rails.

BACKGROUND AND DESCRIPTION OF PRIOR ART

In order for a train to travel over a railroad, track has to be laid ona hard surface. The components include two rails, two tie plates onwhich the rail rests, an underlying cross tie to which the tie platesare attached, with one tie plate on each end of the underlying crosstie, and the rail. The cross ties are laid perpendicular to thedirection of the rails and anchored into a ballast. Typically, thesecomponents are assembled as the track is laid or repaired. The tieplates and the rails are held in place by spikes or something similar.The rails have an upper part, on which the train wheels ride, and alower part called a rail base, which is in contact with the tie plate.

The tie plates typically comprise an iron or steel device that is about5 inches to 10 inches wide and 12 inches to 18 inches long. The tieplates typically have a thickness of about 0.5 inches to 1.0 inch. Onthe tie plates there are two shoulders separated by about 5 inches to 7inches of canted steel, depending on the width of the base of the railin use, where the rail base rests. The part of the tie plate under therail base is tapered in order to set the cant of the rails inward towardthe center of the track. The cant of the rails helps the train wheelsstay on the rails. Typically, cants are 1:10, 1:20, 1:30 and 1:40, butother cants may be required by the railroad company.

As used in this application the term “cant” means the inward inclinationof a rail, affected by the use of inclined-surface tie plates, usuallyexpressed as a rate of inclination, such as 1 in. 40, which means 1.40degrees of slope designed toward the centerline of the cross tie.

A tie plate, which is sometimes called a baseplate, shoulderplate orsole plate, traditionally was a steel plate placed between rails andcross ties. Traditionally, the steel tie plates were fastened to woodencross ties by means of rail spikes or track bolts through the holes intie plates.

One tie plate is located on each end of the cross ties, positioned sothat the space between the inside of the two rails corresponds to thegauge of the track. The US standard railroad gauge (distance between therails) is 4 feet, 8.5 inches.

The standard railroad cross ties for supporting rails are 102 inches inlength, 9 inches wide and 7 inches tall, though different sizes aresometimes used. The cross ties typically are constructed of treatedwood, concrete or composite. The two tie plates on each cross tietypically are constructed of iron or steel. The cross ties are laidperpendicular to the direction of the rail. The rail is attached to themetal tie plates typically with a spike, and the tie plates are attachedto the cross tie with either the same spikes or different spikes.

SUMMARY OF THE INVENTION

A molded railroad composite cross tie unit is disclosed comprising amolded composite cross tie and two molded, non-metallic composite tieplates. This novel molded railroad composite cross tie unit is designedto replace the existing modular railroad metallic tie plates attached towooden cross ties with a single molded unit which is designed to havethe same dimensions as those currently used for railroads. A railroad iscomprised of two rails set about between 4 feet and 5 feet apart, wherethese rails fit into a space on metallic tie plates, where the tieplates and the rails are attached to wooden cross ties, set into aballast by spikes.

The molded railroad composite cross tie unit integrates two molded,non-metallic composite tie plates into the molded composite cross tie.No assembly, other than attaching the rails, is required at the site.The molded railroad composite cross tie units may be used in laying newrail or in repairing damaged or worn out wooden cross ties. The moldedrailroad composite cross tie units comprise the molded composite crosstie and the molded, non-metallic composite tie plate.

The molded composite cross ties comprise two outer sections and a centersection, wherein one molded, non-metallic composite tie plate isintegrated into each of the outer sections of the molded composite crosstie.

The molded railroad composite cross tie units are placed on a ballast,wherein the ballast is comprised of rock or similar material, so thatthe molded composite cross tie is oriented perpendicular to thedirection of the rail.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 depicts a top view of a railroad track with the molded railroadcomposite cross tie units in place.

FIG. 2 depicts a top view of the molded railroad composite cross tieunit including the molded composite cross tie with two molded,non-metallic composite tie plates.

FIG. 3a depicts a side view of the molded, non-metallic composite tieplate located at the left outer end of the molded composite cross tie.

FIG. 3b depicts a side view of the molded, non-metallic composite tieplate located at the right outer end of the molded composite cross tie.

FIG. 4 depicts a side view of the molded railroad composite cross tieunit.

FIG. 5 depicts a rail base attached to the molded, non-metalliccomposite tie plate.

DETAILED DESCRIPTION OF THE INVENTION

A top view of a railroad with molded railroad composite cross tie units(10) placed along railroad tracks (70) is displayed in FIG. 1. Themolded railroad composite cross tie units (10) are perpendicular to therails (60). The molded railroad composite cross tie unit (10) iscomprised of a molded composite cross tie (15), with a first end and asecond end; a first molded, non-metallic composite tie plate (20)integrated into the first end of the molded composite cross tie (15) anda second molded non-metallic composite tie plate (21) integrated intothe second end of the molded composite cross tie (15).

The molded railroad composite cross tie unit (10) depicted in FIG. 2comprises the molded composite cross tie (15), the first molded,non-metallic composite tie plate (20) and the second molded,non-metallic composite tie plate (21). The first molded, non-metalliccomposite tie plate (20) comprises an outer end (50), a center section(30), and an inner end (51). The second molded, non-metallic compositetie plate (21) comprises an outer end (55), a center section (32), andan inner end (56). The same composite material is used for both themolded, non-metallic composite tie plates and the molded composite crosstie.

FIG. 2 shows that there are four holes (22) associated with each of themolded, non-metallic composite tie plates.

Also shown is a first outer shoulder (26) and a first inner shoulder(27) as part of the first molded, non-metallic composite tie plate (20).The first outer end (50) is tapered up towards the first outer shoulder(26). The first outer shoulder (26) is perpendicular to the surface ofthe molded composite cross tie (15). The first inner end (51) is taperedup from the molded composite cross tie (15) towards the first innershoulder (27). The first inner shoulder (27) is perpendicular to thesurface of the molded composite cross tie (15). In between the firstouter shoulder (26) and the first inner shoulder (27) is the centersection (30), which is tapered down from the first outer shoulder (26)to the first inner shoulder (27).

Also shown in FIG. 2 is a second outer shoulder (29) and a second innershoulder (28) as part of the second molded, non-metallic composite tieplate (21). The second outer end (55) is tapered up towards the secondouter shoulder (29). The second outer shoulder (29) is perpendicular tothe surface of the molded composite cross tie (15). The second inner end(56) is tapered up from the molded composite cross tie (15) towards thesecond inner shoulder (28). The second inner shoulder (28) isperpendicular to the surface of the molded composite cross tie (15). Inbetween the second outer shoulder (29) and the second inner shoulder(28) is the second center section (32), which is tapered down from thesecond outer shoulder (29) to the second inner shoulder (28).

FIG. 3a depicts a tilted view of the first molded, non-metalliccomposite tie plate (20). Shown more clearly is the taper of the firstouter section (50) and the first inner section (51). The first outershoulder (26) and the first inner shoulder (27) are parallel to eachother, and both are perpendicular to the surface of the molded compositecross tie (15). The taper of the first center section (30) is alsoshown.

FIG. 3b depicts a tilted view of the second molded, non-metalliccomposite tie plate (21). Shown more clearly is the taper of the secondouter section (55) and the second inner section (56). The second outershoulder (29) and the second inner shoulder (28) are parallel to eachother, and both are perpendicular to the surface of the molded compositecross tie (15). The taper of the second center section (32) is alsoshown.

FIG. 4 depicts the molded railroad composite cross tie unit (10). Alsoshown are holes (22) molded into the molded railroad composite cross tieunit (10) in the molded, non-metallic composite tie plates, (20) and(21). The molded holes (22) may be threaded or straight edges dependingon the manner to be used to attach rails) to the molded railroadcomposite cross tie unit (10).

FIG. 5 depicts the attachment of a rail (60) to the first molded,non-metallic composite tie plate (20). The other rail would be attachedto the second molded, non-metallic composite tie plate (21) in the samemanner. The rail (60) has an upper surface on which a train wheel ridesand a base (80) which is attached to the molded, non-metallic compositetie plate (20) by screws (65) in this embodiment. The holes (22) aremolded into the molded, non-metallic composite tie plate (20). Inanother embodiment the holes (22) are short holes, between about 0.5inches and 1.5 inches, and not threaded, where standard railroad spikesare driven into the molded non-metallic composite tie plates.

The molded composite cross tie (15) is between 8 and 10 feet in length,10 inches to 13 inches wide, and 7 inches to 10 inches thick. At about33 to 39 inches from the center toward the ends of the molded compositecross tie (15), the surfaces (51) and (56) of the molded composite crosstie (15) merge into the molded, non-metallic composite tie plates (20)and (21), where the surface gradually increases to a height of about 0.4inches to 0.7 inches above the surface elevation of the molded compositecross tie (15). The inner shoulders (27) and (28) are formed when theelevation of the surface abruptly decreases by about 0.2 inch to about0.3 inch on the outer sides of the elevated surfaces (51) and (56). Atabout 10 to 20 inches from the ends of the molded composite cross tie(15) toward the center of the molded composite cross tie (15), thesurfaces (50) and (55) of the molded composite cross tie (15) merge intothe molded, non-metallic composite tie plates (20) and (21), where thesurface gradually increases to a height of about 0.4 inches to 0.7inches above the surface elevation of the molded composite cross tie(15). The outer shoulders (26) and (29) are formed when the elevation ofthe surfaces (50) and (55) abruptly decreases by about 0.2 inch to about0.3 inch. The first center section (30) of the first molded,non-metallic composite tie plate (20) is between the shoulders (26) and(27). The second center section (32) of the second molded, non-metalliccomposite tie plate (21) is between the shoulders (28) and (29). Centersections (30) and (32) are canted toward the middle of the moldednon-metallic composite ties plates (20) and (21) to help keep the trainon the rails. These center sections (30) and (32) are the parts of themolded, non-metallic composite tie plates (20) and (21) that are underthe rails (60).

The cant of the center sections (30) and (32) of the molded,non-metallic composite tie plates (20) and (21) is between 1.1 degreesto about 2.8 degrees, but more preferably between about 1.3 degrees and1.8 degrees.

The width of the center sections (30) and (32) of the molded,non-metallic composite tie plates (20) and (21) is designed to fit thewidth of the base of the rail (80) and is typically between 4 inches and7 inches.

The length of each molded, non-metallic composite tie plate, (20) and(21), is between 14 inches and 18 inches. The width of each molded,non-metallic composite tie plate, (20) and (21), is between 5 inches and10 inches. The distance between the first molded, non-metallic compositetie plate (20) and the second molded, non-metallic composite tie plate(21) is determined by the gauge of the rail. The standard US gauge is 4feet, 8.5 inches, and thus the distance from the first inner shoulder(27) and the second inner shoulder (28) is between 4 feet 4 inches and 4feet 1 inch. The gauge may be adjusted to comply with other gauges,which are well known in the industry.

In one embodiment, the molded railroad composite cross tie unit (10) isformed without metal jackets to hold spikes. Starter holes (22) aremolded into the molded, non-metallic composite tie plates (20) and (21),into which spikes may be used to hold the rail in place.

In another embodiment, the molded railroad composite cross tie unit (10)is formed with four threaded steel jackets (22) molded into the molded,non-metallic composite tie plates (20) and (21. Two threaded steeljackets (22) are located on the front side of the molded, non-metalliccomposite tie plates (20) and (21), and two threaded steel jackets (22)are located on the back side of the molded, non-metallic composite tieplates (20) and (21). Threaded screws are sized to fit within thethreaded steel jackets (22) located in the molded, non-metalliccomposite tie plates (20) and (21). The threaded screws hold the rail inplace.

The composite used to form the molded railroad composite cross tie unit(10) was a stiff polymer or other stiff composite with high tensilestrength, typically higher than 100,000 psi. The polymer or compositeexhibited high compressive strength, high shear strength, and excellentresistance to wear and friction. The polymer or composite was selectedfrom the group consisting of linen phenolic, nylon, acrylic polymer,polyimide, glass epoxy, polystyrene, and polybenzimidazole.

1. A molded railroad composite cross tie unit comprising a moldedcomposite cross tie and two molded, non-metallic composite tie plates,a. wherein the molded composite cross tie and the molded, non-metalliccomposite tie plates are constructed of a polymer or composite with hightensile strength, high compressive strength, high shear strength, andhigh resistance to wear and friction; b. wherein the molded compositecross tie is non-wooden; c. wherein the molded railroad composite crosstie unit supports rails for a railroad, with the rails comprising anupper surface on which train wheels ride, and a rail base; d. whereinthe molded, non-metallic composite tie plates comprise an outershoulder, an inner shoulder, and a center section, where the outershoulder and the inner shoulder are separated by a distanceapproximately equal to the width of the rail base; e. wherein the centersection of the molded, non-metallic composite tie plate is tapered sothat the higher side is nearer the outer side of the molded,non-metallic composite tie plate; f. wherein the gauge for the moldedrailroad composite cross tie unit is that required by the railroadcompany; g. wherein the molded composite cross tie has two ends; h.wherein one molded, non-metallic composite tie plate is integrated intoeach end of the molded composite cross tie; i. wherein the molded,non-metallic composite tie plates are positioned between about 0.3 and1.0 inch above the surface of the molded composite cross ties; j.wherein the molded, non-metallic composite tie plates have an outer endand an inner end, where the inner end is located toward the center ofthe molded railroad composite cross tie unit and the outer end islocated away from the center of the molded railroad composite cross tieunit; k. wherein for each molded, non-metallic composite tie plate anouter shoulder and an inner shoulder are formed with a separationapproximately equal to the width of the rail base; and l. wherein aplurality of holes is molded into the molded, non-metallic composite tieplates.
 2. The molded railroad composite cross tie unit as in claim 1where the molded composite cross ties are between 8-10 feet in length,8-10 inches in width and about 3 to 10 inches in thickness.
 3. Themolded railroad composite cross tie unit as in claim 1 where theplurality of holes is threaded with diameters and thread designed toaccept screws with matching thread configuration.
 4. The molded railroadcomposite cross tie unit as in claim 1 where the plurality of holes isnot threaded.
 5. The molded railroad composite cross tie unit as inclaim 1 where the composite is a hard, non-metallic material with atensile strength of a minimum of 100,000 psi.
 6. The molded railroadcomposite cross tie unit as in claim 1 where the composite is selectedfrom the group consisting of linen phenolic, nylon, acrylic polymer,polyimide, glass epoxy, polystyrene, and polybenzimidazole.